Power transmitting apparatus

ABSTRACT

A power transmitting apparatus for performing switching between 2-wheel and 4-wheel drive modes and locking and unlocking of differential mechanism by an operational shaft can include a driving device comprising a reversible motor, a rotational member rotationally driven by the motor and provided with a contacting member. A spring can be arranged on the rotational member, a connecting member can be arranged to be abutted by one end of the spring so as to be rotated by the rotational member via the coil spring, and a driving shaft can be rotatably arranged relative to the rotational member and engaged by the operational shaft in its rotational direction and adapted to be rotated by the rotational member via the connecting member. A stay can be engaged by the driving shaft in its rotational direction and provided with a contacting member. A substrate can be arranged so as to be contacted by the contacting members respectively of the rotational member and the stay and formed with a conducting patterns forming predetermined electric circuits in accordance with the rotational angles respectively of the rotational member and the driving shaft. The rotational member, connecting member, stay and substrate can be formed as separate parts and adapted to be assembled to the driving shaft in order.

PRIORITY INFORMATION

This application is based on and claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2007-127167, filed on May 11, 2007, the entire contents of which is hereby expressly incorporated by reference herein.

BACKGROUND OF THE INVENTIONS

1. Field of the Inventions

The present inventions relate to power transmitting apparatuses for switching between 2-wheel and 4-wheel modes and locking and unlocking differential devices.

2. Description of the Related Art

Four-wheel buggies, also known as “ATVs” (All Terrain Vehicles), usually include power transmitting apparatuses for connecting and disconnecting power from an engine to the front wheels, which are not-driven wheels, and also switching between 2-wheel and 4-wheel drive modes. Such a vehicle is disclosed in Japanese Laid-open Patent Publication No. 191768/2003.

Generally, the power transmitting apparatus is provided with a differential mechanism (differential gear set) to provide smooth turning of vehicle by absorbing the difference of rotation between left and right wheels. Japanese Laid-open Patent Publication No. 509409/1994 discloses another type of differential system that does not a differential gear set.

Some known designs can limit the differential action of one wheel by incorporating a power transmitting apparatus provided with means for locking the differential mechanism (differential-locking means) in order to prevent a reduction of driving torque under circumstances in which one of left and right wheels of vehicle would be mired in a slippery road such as mud. A more recently proposed design of a power transmitting apparatus include a motor for connecting and disconnecting the driving force and locking and unlocking of a differential mechanism.

For example, one prior art power transmitting apparatus includes an electric motor arranged in either of the left or right sides of a case forming a box of the power transmitting apparatus. The connection and disconnection between an input shaft connected to an engine and an output shaft connected to a front wheel as well as the locking and unlocking of a differential mechanism are performed by actuating a fork connected to an actuator driven by the electric motor.

Japanese Laid-open Patent Publication No. 324719/2005 discloses a driving device for actuating a fork that connects and disconnects or that performs locking and unlocking of the operating device. In this system, the driving shaft engaged by the operating device for actuating the fork, is projected from a sub case (containing case). In addition the sub case, which forms a case for the driving means, is sealed and structured so that the driving force of the motor can be transmitted to the operational means via the driving shaft by engaging the operational means with an end of the driving shaft projected from the sub case.

More specifically, Japanese Laid-open Patent Publication No. 324719/2005 discloses a rotational member (driving gear 21) driven by an electric motor and formed with a contacting member, a coil spring (23) arranged on the rotational member, a connecting member (rotation holding member 24) arranged to be abutted by one end of the coil spring and rotated by the rotational member via the coil spring, a driving shaft (output shaft 22) rotatable relative to the rotational member and rotated by the rotational member, a stay (holder 28) engaged by the driving shaft in its rotational direction and formed with a contacting member, and a substrate (circuit substrate 40) formed with conducting patterns able to form predetermined electric circuits in accordance with the rotational angles of the rotational member and the driving shaft.

In the power transmitting apparatus of the prior art, the assembly of a driving means has been performed by mounting the connecting member and the rotational member caulked on the driving shaft after the stay had been mounted within the sub case and the substrate covering the stay had been mounted. A tip end of the driving shaft is formed as a “D” shaped cut (“D” shaped cross-section) and a through aperture having a configuration corresponding to the “D” shaped driving shaft is formed in the stay. The stay is anchored in the rotational direction of the driving shaft by inserting the tip end of the driving shaft integral with the connecting member into the rotational member and the substrate and then by anchoring the stay on the driving shaft in its rotational direction with anchoring the through aperture of the stay to the “D” cut shaft of the driving shaft. Thus a predetermined phase (relative rotational angle) can be obtained between the stay and the driving shaft.

SUMMARY OF THE INVENTIONS

An aspect of at least one of the embodiments disclose herein includes the realization that there is a problem in the power transmitting apparatus of the prior art that it is difficult to align the tip end of the driving shaft with the “D” shaped aperture of the stay when anchoring the stay to the tip end of the driving shaft. That is, since the through aperture of the stay cannot be watched by a worker with it being interrupted by the substrate, the rotational member or the connecting member integrated with the driving shaft, the tip end of the driving shaft has been anchored to the trough aperture of the stay with taking aim gropingly (by “feel”). This has extremely reduced the workability of assembly of the driving device.

Thus, in accordance with an embodiment, a power transmitting apparatus for performing switching between 2-wheel and 4-wheel drive modes and locking and unlocking of differential mechanism by an operational shaft can comprise an input shaft connected to an engine of a vehicle and rotated around a rotational axis. Left and right side output shafts can be configured to drive front wheels or rear wheels of the vehicle when a driving force is transmitted from the input shaft. A differential mechanism can be arranged between the input shaft and the output shafts and can be configured to absorb the difference of rotation between the output shafts by differential action thereof An operational shaft can be configured to connect and disconnect the input shaft from the output shafts by connecting and disconnecting the input shaft and the output shafts and being configured to lock and unlock the differential mechanism. A driving device can be configured to drive the operational shaft. A main case can be mounted on the vehicle and can contain the differential mechanism and the operational shaft therein. The driving device can comprise a reversible motor, a rotational member rotationally driven by the motor and provided with a contacting member, and a spring arranged on the rotational member. A connecting member can be arranged to be abutted by one end of the spring so as to be rotated by the rotational member via the coil spring. A driving shaft can be rotatably arranged relative to the rotational member and engaged by the operational shaft in its rotational direction and adapted to be rotated by the rotational member via the connecting member. A stay can be engaged by the driving shaft in its rotational direction and provided with a contacting member. A substrate can be arranged so as to be contacted by the contacting members respectively of the rotational member and the stay and formed with a conducting patterns forming predetermined electric circuits in accordance with the rotational angles respectively of the rotational member and the driving shaft. The rotational member, connecting member, stay and substrate can be formed as separate parts and can be adapted to be assembled to the driving shaft in order.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional advantages and features of the present inventions are apparent from the below description and the appended claims, taken in conjunction with the accompanying drawings, wherein:

FIG. 1 is a schematic view showing a vehicle to which various embodiments of the power transmitting apparatus disclosed herein can be applied;

FIG. 2 is a cross-sectional view showing the power transmitting apparatus in accordance with an embodiment;

FIG. 3 is a schematic view showing the inside structure of a driving device of the power transmitting apparatus;

FIG. 4 is a cross-sectional view showing the power transmitting apparatus in a condition switched to the 4-wheel driving;

FIG. 5 is a cross-sectional view showing the power transmitting apparatus in a locked condition of the differential apparatus;

FIG. 6 is a development of the operational shaft showing the side face cam groove of the power transmitting apparatus;

FIG. 7 is a schematic view showing the fork actuated along the side face cam groove of the power transmitting apparatus;

FIG. 8 is an end view of the operational shaft showing the end face cam groove of the power transmitting apparatus;

FIG. 9 is a schematic view showing the fork actuated along the end face cam groove of the power transmitting apparatus;

FIG. 10 is a schematic view showing the sleeve engaging the fork actuated along the end face cam groove;

FIG. 11 is a perspective view of engaging end faces of the operational shaft and the driving shaft taken from one direction thereof;

FIG. 12 is a perspective view of engaging end faces of the operational shaft and the driving shaft taken from the other direction thereof;

FIG. 13 is an exploded perspective view showing the order of assembly of the connecting member, the rotational member, the substrate and the stay to the driving shaft of the driving means in the power transmitting apparatus; and

FIG. 14 is an exploded perspective view showing an assembling process of the driving shaft to the main case of the power transmitting apparatus seen from a direction different from that of FIG. 13.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As shown in FIG. 1 a power transmitting apparatus cane be mounted between front wheels 2 a and 2 b in a front region of a vehicle such as a 4-wheel buggy or an ATV (All Terrain Vehicle) for performing the switching between 2-wheel and 4-wheel drive modes as well as locking and unlocking of a differential device. The power transmitting apparatus is disclosed in the context of an ATV because it has particular utility in this context. However, the power transmitting apparatus can be used in other contexts, such as, for example, but without limitation, other vehicles including land vehicles.

As shown in FIG. 1 a propulsion shaft 4 extends from an engine (driving power source) “E” toward the rear of a vehicle to drive rear wheels 3 a and 3 b respectively via driving shafts 5 a and 5 b. Another propulsion shaft 6 (input shaft) also extends from the engine “E” and is connected to the power transmitting apparatus 7. These propulsion shafts 4 and 6 are connected to the engine “E” to be rotated around their axes.

A pair of left and right driving shafts (output shafts) 8 a and 8 b are connected to left and right sides “b” of the power transmitting apparatus 7 and drive the front wheels 2 a and 2 b of the vehicle 1 when driving force of the propulsion shaft 6 is transmitted to the power transmitting apparatus. That is, when the vehicle 1 is in the 4-wheel drive mode, since the driving force of engine “E” inputted to the power transmitting apparatus 7 is transmitted to the front wheels 2 a and 2 b via the driving shafts 8 a and 8 b, the front wheels 2 a and 2 b are also rotated in addition to the rear wheels 3 a and 3 b. On the other hand, when the vehicle 1 is in the 2-wheel drive mode, the driving force of the engine “E” inputted to the power transmitting apparatus 7 is not transmitted to the driving shafts 8 a and 8 b and thus the front wheels 2 a and 2 b not-driven wheels as described in more detail below.

As shown in FIGS. 2, 4 and 5, the power transmitting apparatus 7 can have a main case 9 formed by two halves (a first case 9 b and a second case 9 a) for containing therein a driving member 13, a driven member 14, a differential mechanism (or “differential device”) 10, and an operational shaft 11 etc. In some embodiments, the driving shaft 8 a can extend from a side “b” of the second case 9 a, and the driving shaft 8 b can extend from a side “b” of the first case 9 b. The propulsion shaft 6 can extend from a rear side “a” of the first case 9 b facing to the engine “E”.

The driving member 13 can be rotationally supported by a bearing B1 and connected to the propulsion shaft 6 via a spline fitting and thus can be rotated together with the propulsion shaft 6 around an axis L1. The driven member 14 can be rotationally supported by bearings B2 and B3 and connected to the driving member 13 via a sleeve A1 (described below) and thus rotated around the axis L1 when the rotational driving force is transmitted thereto.

Teeth 14 a forming a gear, can be formed on a circumferential surface of the driven member 14 and mesh with teeth 15 a of the housing 15 of the differential mechanism 10. Accordingly, the housing 15 is rotated via meshing of teeth 14 a and 15 a when the driven member 14 is rotated.

Differential mechanisms, such as the differential mechanism 10, are well-known to provide smooth turning of the vehicle 1 by absorbing the difference of rotation between the driving shafts 8 a and 8 b due to differential of output cam member 10 a and 10 b interposed between the propulsion shaft 6 and the driving shafts 8 a and 8 b. For example, similarly to that disclosed in the Japanese Laid-open Patent Publication No. 509409/1994, the pair of output cam members 10 a and 10 b having splines 10 aa and 10 ba for receiving splines of the driving shafts 8 a and 8 b are contained within the housing 15 and arranged so that they can rotate relative to the housing 15 around an axis L2.

The output cam members 10 a and 10 b are formed with wave shaped cam surfaces 10 ab and 10 bb respectively. The cam surface 10 ab is formed for example by an annular zigzagged surface comprising six pairs of mutually inclined helical surfaces and the cam surface 10 bb is formed by six pairs of mutually inclined helical surfaces corresponding to the cam surface 10 ab. A plurality of cam followers 10 c are arranged between these cam surfaces 10 ab and 10 bb. A reference numeral S1 in drawings denotes a leaf spring configured to bias the output cam member 10 b toward the cam member 10 a.

During operation of the vehicle 1 on a straight way, the cam followers 10c apply load to the cam surfaces 10 ab and 10 bb so as to rotate the cam members 10 a and 10 b at same speed as that of the housing 15. On the other hand, during operation of the vehicle 1 through a curve, a difference is caused in rotational speed between the cam members 10 a and 10 b due to the difference of numbers of the cam surfaces 10 ab and 10 bb of the output cam members 10 a and 10 b. That is, during turning of the vehicle 1, the output cam members 10 a and 10 b rotate at different speeds relative to the housing 15 and thus absorb the difference of the number of rotation between the driving shafts 8 a and 8 b (i.e. difference of rotational speed between the inner wheel and the outer wheel of the front wheels 2 a and 2 b).

The operational shaft 11 can have one function of connection and disconnection between the propulsion shaft (input shaft) 6 and driving shafts (output shafts) 8 a and 8 b and thus connection and disconnection of the transmission of rotational force of the propulsion shaft 6 to the driving shafts 8 a and 8 b, and another function of locking and unlocking of the differential action of the differential mechanism 10 (differential-locking operation). That is, the operational shaft 11 rotates around the axis L3 and can perform the connection and disconnection between the input shaft 6 and output shafts 8 a and 8 b as well as the differential-locking operation of the differential mechanism 10.

The operational shaft 11 can comprise a smaller diameter portion 11 a and a larger diameter portion 11 b mounted on one end of the smaller diameter portion 11 a and the smaller diameter portion 11 a is rotationally supported by a bearing B6 and the larger diameter portion 11 b is rotationally supported by a bush B7. The smaller diameter portion 11 a and the larger diameter portion 11 b can be simultaneously rotated around the axis L3 when they are driven by a differential device 10 (described below). That is, both ends of the operational shaft 11 are rotationally supported as a whole by the bearing B6 and the bush B7.

As shown in FIG. 6, the side face of the operational shaft 11 (the side face of the smaller diameter portion 11 a) is formed with a side face cam groove 11 aa for actuating a first fork F1 and a pin P2 is adapted to be inserted into the side face cam groove 11 aa. The base end of the first fork F1 is formed with an aperture F1 a for passing the operational shaft 11 (smaller diameter portion 11 a) therethrough as shown in FIG. 7. That is, the first fork F1 is straddled on the operational shaft 11 at the base end thereof and the pin P2 is press fitted in the base end of the first fork F1 at the bottom of the aperture F1 a so that it is directed to the side face cam groove 11 aa.

Accordingly when the operational shaft 11 is rotated, the pin P2 is moved along the side face cam groove 11 aa and thus the first fork F1 is moved along the operational shaft 11. The fore end of the first fork F1 is engaged with a sleeve A1 and the sleeve A1 is moved along the driving member 13 toward a spline formed on the driven member 14 and engaged therewith as shown in FIG. 4. Thus the driving member 13 and the driven member 14 are connected each other and accordingly the propulsion shaft 6 and the driving shafts 8 a and 8 b are also connected. In this condition, the front wheels 2 a and 2 b function as driven wheels and the vehicle 1 is in a switched condition to the 4-wheel drive mode.

Thereafter when the operational shaft 11 is rotated in a reverse direction, the pin P2 is moved along the side face cam groove 11 aa and accordingly the first fork F1 is guided on the operational shaft 11 and returned to its initial position shown in FIG. 2. Thus the sleeve A1 is also returned its initial position shown in FIG. 2 and the driving member 13 and the driven member 14 are disconnected. Thus the vehicle 1 is now switched again from the 4-wheel to the 2-wheel drive mode.

On the other hand, the end face of the larger diameter portion 11 b of the operational shaft 11 is formed with an end face cam groove 11 ba for actuating a second fork F2 and a pin P3 is adapted to be inserted therein as shown in FIG. 8. As shown in FIG. 9, the second fork F2 is arranged so that it lies on an extension line of the operational shaft 11 (axis L3). The pin P3 is press fitted in the base end of the second fork F2 and the fore end of the second fork F2 is engaged with a sleeve A2.

Accordingly when the operational shaft 11 is rotated, the pin P3 is moved along the end face cam groove 11 ba and thus the second fork F2 is actuated to move the sleeve A2 upward in FIG. 2. The end face cam groove 11 ba is structured so that it actuates the second fork F2 after the propulsion shaft 6 and the driving shafts 8 a and 8 b are connected with the first fork F1 is being actuated due to the rotation of the operational shaft 11.

As shown in FIG. 10, a plurality (three in the illustrated embodiment) of pins PI are integrally mounted on the sleeve A2 and they are adapted to be inserted in apertures 10 ac formed in the output cam member 10 a as shown in FIG. 5. When the pins p1 are inserted in the apertures 10 ac of the output cam member 10 a, the output cam member 10 a is connected to the housing 15, thereby locking the differential, also referred to as the “differential-locking condition”.

Thereafter, when the operational shaft 11 is rotated in a reverse direction, the pin P3 is moved along the end face cam groove 11 ba and accordingly the second fork F2 is returned to its initial position shown in FIG. 2. Thus the sleeve A2 is also returned its initial position shown in FIG. 2 and the pins P1 are pulled out from the apertures 10 ac of the output cam member 10 a. Thus, the differential is now unlocked, thereby returning the vehicle 1 to the “differential-unlocking condition” permitting the differential action of the differential mechanism 10.

As shown in FIGS. 2 and 3, the driving device 12 can comprise an electric motor “M”, a gear combination formed by a worm gear G1 and a gear G2, a driving shaft 16, a rotational member 18, a spring “S”, a connecting member 17, a substrate 19, a stay 20 and a sub case “Y” forming a box of the driving device 12. The motor “M” can rotate its output shaft “Ma” in a reverse direction. The worm gear G1 is connected to the output shaft “Ma” of the motor “M” and rotated by the motor “M”.

The gear G2 can comprise a larger gear G2 a and a smaller gear G2 b (FIG. 2). The larger gear G2 a mates the worm gear G1 and the smaller gear G2 b mates teeth formed on a circumferential surface of the rotational member 18. The rotational member 18 contains the spring “S” in a containing portion 18 c (see FIG. 13) formed along the circumferential direction of the rotational member 18 and can rotate around the axis L3 together with the spring “S” interlocking with rotation of the gear G2.

The driving shaft 16 can be configured to be passed through an aperture 18 a (FIG. 13) of the rotational member 18 and rotated around the axis L3. A connecting member 17 can be secured on the end face of the rotational shaft member 16. For example, a through aperture 17 b for insertion of the driving shaft 16 is formed substantially at its center and has a “D” shaped configuration corresponding to a “D” shaped cut surface “β”. That is, the connecting member 17 and the driving shaft 16 are connected so that they cannot rotate relatively each other by inserting the driving shaft 16 into the through aperture 17 b of the connecting member 17.

A bent portion 17 a can be formed on the connecting member 17 so that it abuts one end of the spring “S”. Accordingly when the rotational member 18 is rotated by the motor “M”, its rotational force is transmitted to the connecting member 17 via the spring “S” to rotate the driving shaft 16. A contacting member 18 b (FIG. 14) is mounted on the bottom surface of the rotational member 18 so that it can contact a substrate 19 described in greater detail below.

As shown in FIG. 11 the end face of the driving shaft 16 facing to that of the operational shaft II for engaging therewith is formed with a “two-sided” (16 aa and 16 ab) key groove 16 a passing through the driving shaft 16 in its diametrical direction and a center aperture 16 b formed within the key groove 16 a on a central axis of the driving shaft 16. On the contrary, the engaging end face of the operational shaft 11 facing to that of the driving shaft is formed with a key projection 11 c complementarily received within the key groove 16 a and a center projection also received within the center aperture 16 b of the driving shaft 16 as shown in FIG. 12.

It should be understood that the term “two-sided” means two side surfaces apart a predetermined distance and that the key groove 16 a is somewhat longer than the key projection 11 d. Although it is shown in the illustrated embodiment of FIGS. 11 and 12 that the driving shaft 16 is formed with the key groove 16 a and the center aperture 16 b and the operational shaft is formed with the key projection 11 c and the center projection 11 d, it is possible to form the key groove and the center aperture on the operational shaft 11 and the key projection and the center projection on the driving shaft 16.

That is, it is possible to form on the end face of the operational shaft 11 facing to that of the operational shaft 16 for engaging therewith is formed with the two-sided key groove passing through the operational shaft 11 in its diametrical direction and the center aperture formed within the key groove on the central axis of the operational shaft 11, and the engaging end face of the driving shaft 16 facing to that of the operational shaft is formed with the key projection complementarily received within the key groove and the center projection also received within the center aperture of the operational shaft 11.

The centering of the driving shaft 16 and the operational shaft 11 can be achieved by aligning the center projection 11 d with the center aperture 16 b and by rotating the operational shaft 11 relative to the driving shaft 16 so as to aligning the key projection 11 c with the key groove 16 a. In addition since all the center aperture 16 b, center projection 11 d, key groove 16 a and key projection 11 c can be easily machined in the driving shaft 16 and the operational shaft 11 having a small diameter, the centering as well as the engagement between the driving shaft 16 and the operational shaft 11 can be accurately performed.

In some embodiments, the sub case “Y” can contain therein structural elements such as the electric motor “M”, the driving shaft 16 etc. and can be adapted to be mounted on the rear side “a” of the main case 9. The sub case “Y” can be formed with an opening “Ya” having a size permitting the end face of the driving shaft 16 engaged with the operational shaft 11 to be exposed and the operational shaft 11 to be inserted therethrough. In addition an oil seal 22 is arranged on the inner circumferential surface of the opening “Ya” and an O-ring 21 is arranged on the outer circumferential surface of the opening “Ya” of the sub case “Y”.

The oil seal 22 can be arranged on the inner circumferential surface of the opening “Ya” at a position away from the driving shaft 16 and structured to hermetically seal the inside of the sub case “Y” with sealing an interface between the outer circumferential surface of the operational shaft 11 and the inner circumferential surface of the opening “Ya” when the operational shaft 11 is engaged with the driving shaft 16. That is, prior to assembly of the sub case “Y” to the main case 9, the sub case “Y” will not be hermetically sealed since the driving shaft 16 is positioned away from the oil seal 22.

The centering of the driving shaft 16 and the operational shaft 11 can be achieved by passing the operational shaft 11 through the opening “Ya”, then by aligning the center projection 11 d with the center aperture 16 b and finally by rotating the operational shaft 11 relative to the driving shaft 16 so as to aligning the key projection 11 c with the key groove 16 a. Thus the operational shaft 11 is sealed with its outer circumferential surface being contacted by the oil seal 22 and the main case 9 is also sealed with the O-ring 21 being contacted by the main case 9.

According to some embodiments, the stay 20, the substrate 19, the rotational member 18 and the connecting member 17 are inserted onto the driving shaft 16 and assembled thereto with the stay 20 and the connecting member 17 being anchored to the driving shaft 16. In addition the power transmitting apparatus further comprises a circlip 23 as means for preventing fall-out of the connecting member 17 from the driving shaft 16 after having assembled the stay 20, the substrate 19, the rotational member 18 and the connecting member 17 to the driving shaft 16 in order with anchoring the stay 20 and the connecting member 17 to the driving shaft 16.

The stay 20 is engaged with the driving shaft 16 in its rotational direction and provided with a contacting member 20 b. The stay is formed with a through aperture 20 a at the center thereof to be inserted by the driving shaft 16 and has a “D” shaped configuration corresponding to a “D” shaped cut surface “α” of the driving shaft 16. Thus the stay 20 and the driving shaft 16 are engaged each other so as not to be relatively rotated by engagement of their “D” shaped through aperture 20 a and the “D” shaped cut surface “α” .

The substrate 19 can be formed with both of its sides having conducting patterns at positions to which the contacting members 18 b (FIG. 14) and 20 b respectively of the rotational member 18 and the stay 20 contact and adapted to be mounted on the sub case “Y” by fasteners such as screws. The conducting patterns are structured so that they form predetermined electric circuits in accordance with the rotational angles of the rotational member 18 and the stay 20 (i.e. the driving shaft 16). That is, the contacting members 18 b and 20 b slide on the conducting patterns and form the predetermined electric circuit corresponding to relative rotational angle between the rotational member 18 and the driving shaft 16 when they rotate relative to the substrate 19.

For assembling the structural elements described above, firstly the stay 20 can be assembled to the driving shaft 16 by inserting the driving shaft 16 into the through aperture 20 a of the stay 20 and engaging the “D” shaped cut portion “α” with the “D” shaped through aperture 20 a. Similarly the substrate 19 is assembled to the driving shaft 16 by inserting the driving shaft 16 into the through aperture 19 a of the substrate and then the rotational member 18 is also assembled to the driving shaft 16 by inserting the driving shaft 16 into the through aperture 18 a of the rotational member 18. During which the contacting members 20 b and 18 b respectively of the stay 20 and the rotational member 18 are assembled so that they contact the conducting patterns of the substrate 19.

Finally, the connecting member 17 is assembled to the driving shaft 16 by inserting the driving shaft 16 into the through aperture 17 b of the connecting member with engaging the “D” shaped cut surface “β” with the “D” shaped through aperture 17 b. These structural elements are prevented from falling out from the driving shaft 16 by mounting the circlip 23 on the driving shaft after the connecting member 17 having been assembled to the driving shaft.

Under such an assembled condition when the motor “M” is actuated, the rotational force is transmitted to the driving shaft 16 via the worm gear G1, the gear G2, the rotational member 18, the spring “S” and the connecting member 17 and accordingly the operational shaft 11 engaged by the driving shaft 16 is rotated. The electric circuits formed by sliding of the contacting members 18 b and 20 b respectively of the rotational member 18 b and the stay 20 on the conducting patterns can detect a rotational angle of the rotational member 18 (i.e. rotational angle of the motor side) and a rotational angle of the stay 20 (i.e. rotational angle of the driving shaft 16 and the operational shaft 11).

During operation, in order to switch the vehicle 1 from the 2-wheel to the 4-wheel drive mode, the motor “M” is actuated to rotate the operational shaft 11 (the smaller diameter portion 11 a and the larger diameter portion 11 b) around the axis L3. This causes the fork F1 to be slid along the smaller diameter portion 11 a of the operational shaft 11 in order to engage the splines of the sleeve A1 and the driven member 14 each other.

On the other hand, when the spline of the sleeve A1 does not align the corresponding spline of the driven member 14, the rotation of the driving device 12 (concretely the rotational member 18) is absorbed due to contraction of the spring “S”. In this case although there is caused a difference in the rotational angles between the rotational member 18 rotated by the motor “M”, and the driving shaft 16 and the operational shaft 11, the rotational angle at the side of the rotational member 18 can be detected from the position of the contacting member 18 relative to the conducting pattern of the substrate 19, and the rotational angle at the side of the driving shaft 16 can be detected from the position of the contacting member 20 b relative to the conducting pattern of the substrate 19.

Accordingly the rotation of the operational shaft 11 is stopped until the spline of the sleeve A1 is engaged with the spline of the driven member 14 with continuing the actuation of the motor “M”. When the spline of the sleeve A1 is engaged with the corresponding spline of the driven member 14, the spring “S” extends to move the sleeve A1 to the specific position and to fit the splines of the sleeve A1 and the driven member 14 each other. Thus the driving member 13 and the driven member 14 are connected to each other. Accordingly the propulsion shaft 6 and the driving shaft 8 a and 8 b are also connected each other and thus the driving force of the engine “E” is transmitted to both the rear wheels 3 a and 3 b and the front wheels 2 a and 2 b (4-wheel driving).

During the operational process mentioned above, the pin P3 is kept in the circular arc portion of the end face cam and thus the second fork F2 is not actuated. If it is desired to lock the differential mechanism 10 (differential-locking), the motor “M” is further rotated to rotate the operational shaft 11 (the smaller diameter portion 11 a and the larger diameter portion 11 b) around the axis L3. This causes the second fork F2 to be moved along the end face cam groove 11 ba of the larger diameter portion 11 b. Thus the sleeve A2 is moved upward in FIG. 2 to cause the pins PI to be inserted into the aperture 10 ac of the output cam member 10 a.

When the pins P1 of the sleeve A2 do not align the aperture 10 ac, the rotation of the driving device 12 (for example, the rotational member 18) is absorbed due to contraction of the spring “S”. In this case although there is caused a difference in the rotational angles between the rotational member 18 rotated by the motor “M”, and the driving shaft 16 and the operational shaft 11, the rotational angle at the side of the rotational member 18 can be detected from the position of the contacting member 18 relative to the conducting pattern of the substrate 19, and the rotational angle at the side of the driving shaft 16 can be detected from the position of the contacting member 20 b relative to the conducting pattern of the substrate 19.

Accordingly the rotation of the operational shaft 11 is stopped until the pins P1 of the sleeve A2 aligns and fits into the aperture 10 ac with keeping the actuation of the motor “M”. When the pins P1 are aligned with the corresponding apertures 10 ac, the spring “S” extends to move the sleeve A2 to the specific position and to insert the pins P1 into the apertures 10 ac. Thus the output cam member 10 a and the housing 15 are connected each other and the differential action of the differential mechanism 10 is locked (differential-locking).

If rotating the motor “M” in the reverse direction, the operational shaft 11 is also rotated in the reverse direction around its axis L3. Accordingly the unlocking of the differential mechanism 10 (differential-unlocking) as well as disconnection of the propulsion shaft 6 and the driving shafts 8 a and 8 b (2-wheel driving) can be performed successively. That is, according to the power transmitting apparatus 7 of the present invention, it is possible to arbitrarily perform the switching between the 2-wheel driving and the 4-wheel driving of the vehicle 1 as well as locking and unlocking of the differential mechanism 10 by the operational shaft 11.

According to the present invention, since the rotational member 18, the connecting member 17, the stay 20 and the substrate 19 are formed as separated member and can be assembled to the driving shaft in order, an worker can watch each member during its assembly to the driving shaft. Especially the engaging working of the stay 20 and the connecting member 17 with the driving shaft 16 in their rotational direction can be easily performed.

In addition since the stay 20, the substrate 19, the rotational member 18 and the connecting member 17 can be prevented from being fallen out from the driving shaft 16 by mounting the circlip 23 on the driving shaft after the connecting member 17 having been assembled to the driving shaft, the assembly of the driving device 12 can be easily performed and thus the workability in assembly of the driving device 12 can be further improved.

Further, according to some embodiments, the sub case “Y” is not hermetically closed during assembly of the operational shaft 11 to the driving device 12 since the end face of the driving shaft 16 to be engaged with the operational shaft 11 is exposed through the opening “Ya” formed in the sub case “Y” and the operational shaft 11 is inserted therethrough to engage the driving shaft 16. This is achieved without increase of the number of structural elements and accordingly the workability of assembly of the operating shaft 11 and the driving shaft 16 can be improved. In addition the main case 9 and the sub case “Y” can be sealed each other by the O-ring 21 during the assembling process of the operational shaft 11 to the driving shaft 16 with passing the operational shaft 11 through the opening “Ya”.

In addition since the first fork F1 is mounted so that its the base end straddles on the operational shaft 11 and guided by the operational shaft 11, it is possibly to surely perform the connection and disconnection between the propulsion shaft (input shaft) 6 and the driving shafts (output shafts) 8 a and 8 b and thus to eliminate any other guiding means. Thus it is possible to improve the workability of assembly due to reduction of the number of structural parts and also possible to improve the freedom of layout within the main case 9.

The operational shaft 11 is rotationally supported at its both ends and thus has strong strength as compared with that supported by a cantilever structure sufficient to support a load applied via the first fork. Particularly, according to some embodiments, the operational shaft 11 can sufficiently support such a large load that would be caused in the side face cam groove 11 aa when the configuration of spline of the sleeve A1 does not align the corresponding spline of the driven member 14.

The present inventions can be applied to any other power transmitting apparatus having outline configurations or additional functions different from those illustrated and described in the present application if the power transmitting apparatus has the driving means comprising the rotational member, the connecting member, the stay and the substrate which are separate from the driving shaft and can be assembled to the driving shaft in order.

Obviously, modifications and alternations will occur to those of ordinary skill in the art upon reading and understanding the preceding detailed description. It is intended that the present inventions be construed as including all such alternations and modifications insofar as they come within the scope of the appended claims or the equivalents thereof For example the present inventions can be applied to a vehicle other than an automobile. In such a case the driving power of an engine may be always transmitted to front wheels and switching between the two-wheel driving and the four-wheel driving may be performed by connecting and disconnecting the power transmission to rear wheels. The engagement between the driving shaft 16 and the stay 20 and the connecting member 17 via the “D” shaped cut surface can be replaced by other engaging configuration (e.g. two-sided projection and recess). The order of assembly of the associated parts to the driving shaft 16 may be changed so long as it does not give any influence to the function of the power transmitting apparatus. In addition the differential mechanism 10 formed by one pair of output cam members contained within the housing of the illustrated embodiment may be replaced by any other general differential mechanism e.g. using planetary gears. 

1. A power transmitting apparatus for performing switching between 2-wheel and 4-wheel drive modes and locking and unlocking of differential mechanism by an operational shaft comprising: an input shaft connected to an engine of a vehicle and rotated around a rotational axis; left and right side output shafts configured to drive front wheels or rear wheels of the vehicle when a driving force is transmitted from the input shaft; a differential mechanism arranged between the input shaft and the output shafts and configured to absorb the difference of rotation between the output shafts by differential action thereof; an operational shaft configured to connect and disconnect the input shaft from the output shafts by connecting and disconnecting the input shaft and the output shafts and being configured to lock and unlock the differential mechanism; a driving device configured to drive the operational shaft; and a main case mounted on the vehicle and containing the differential mechanism and the operational shaft therein, wherein the driving device comprises: a reversible motor; a rotational member rotationally driven by the motor and provided with a contacting member; a spring arranged on the rotational member; a connecting member arranged to be abutted by one end of the spring so as to be rotated by the rotational member via the coil spring; a driving shaft rotatably arranged relative to the rotational member and engaged by the operational shaft in its rotational direction and adapted to be rotated by the rotational member via the connecting member; a stay engaged by the driving shaft in its rotational direction and provided with a contacting member; a substrate arranged so as to be contacted by the contacting members respectively of the rotational member and the stay and formed with a conducting patterns forming predetermined electric circuits in accordance with the rotational angles respectively of the rotational member and the driving shaft, said rotational member, connecting member, stay and substrate being formed as separate parts and adapted to be assembled to the driving shaft in order.
 2. A power transmitting apparatus of claim 1 further comprising means for preventing fall-out of the connecting member from the driving shaft after having assembled the stay, the substrate, the rotational member and the connecting member to the driving shaft in order with anchoring the stay and the connecting member to the driving shaft.
 3. A power transmitting apparatus of claim 1, wherein the end face of the driving shaft configured to engage the end face of the operational shaft is formed with a two-sided key groove passing through the driving shaft in its diametrical direction as well as a center aperture formed within the key groove on a central axis of the driving shaft, and wherein the end face of the operational shaft for engaging the end face of the driving shaft is formed with a key projection complementarily received in the key groove of the driving shaft as well as a center projection formed on a central axis of the operational shaft so as to be complementarily received in the center aperture of the driving shaft.
 4. A power transmitting apparatus of claim 2, wherein the end face of the driving shaft configured to engage the end face of the operational shaft is formed with a two-sided key groove passing through the driving shaft in its diametrical direction as well as a center aperture formed within the key groove on a central axis of the driving shaft, and wherein the end face of the operational shaft for engaging the end face of the driving shaft is formed with a key projection complementarily received in the key groove of the driving shaft as well as a center projection formed on a central axis of the operational shaft so as to be complementarily received in the center aperture of the driving shaft.
 5. A power transmitting apparatus of claim 1, wherein the end face of the operational shaft configured to engage the end face of the driving shaft is formed with a two-sided key groove passing through the operational shaft in its diametrical direction as well as a center aperture formed within the key groove on a central axis of the operational shaft, and wherein the end face of the driving shaft configured to engage the end face of the operational shaft is formed with a key projection complementarily received in the key groove of the operational shaft as well as a center projection formed on a central axis of the driving shaft so as to be complementarily received in the center aperture of the operational shaft.
 6. A power transmitting apparatus of claim 2, wherein the end face of the operational shaft configured to engage the end face of the driving shaft is formed with a two-sided key groove passing through the operational shaft in its diametrical direction as well as a center aperture formed within the key groove on a central axis of the operational shaft, and wherein the end face of the driving shaft configured to engage the end face of the operational shaft is formed with a key projection complementarily received in the key groove of the operational shaft as well as a center projection formed on a central axis of the driving shaft so as to be complementarily received in the center aperture of the operational shaft. 